Enhancement of production capacity and process optimization for the helicopter final assembly

Abstract

In order to meet progressive increase in demands of customer necessities (Voice of customer) and to sustain in the competitive global aerospace market, Helicopter Division has to increase its production output. Even though the efforts are being made to increase production rate with increase in capacity, the rate of increase achieved is not optimal to meet the customer/market demand. The main drawback of any such analysis is, unavailability of direct quantitative relation with the production capacity and future demands (which is uncertain), this also poses a potential risk of over investment. The project deals with the study of improving the production rate of Helicopter Assembly without any under efficient investment and by optimizing the process and resources. Capacity Enhancement and Process Optimization can be achieved by having a detailed study and analysis of the following factors: Establishing parallel assembly line of H/C production considering space and logistics constraints. (Presently having only single line of production.)Human resource optimization by sorting and allocation of Man Power in terms of Helicopter wise build up, rather than by Module/Trade wise which is presently being followed. Improvement in supply chain management which includes material procurement, Kitting, Kit loading and C-Class items loading. Maintaining Tailor made Tool Kits for critical/specified activities/operation. Developing and Maintaining Database for every helicopter for recording specific problems/snags and their solutions/dispositions for Future Reference. Outcome of the Project: Increase the production output of final assembly with effective use of synergy available with the resources on hand or being added in due course and their optimal utilization without any additional investment.(b) Career development of employees by means of skills up gradation by handling multiple trade/module which helps in motivating them to work with more authority and accountability to provide better productivity and quality. It also ensures the equal distribution of workloads.